Solutions for Ecological Printing

Solutions for
Ecological Printing

Content
4 Environmental Management
8 Paper
10 Workflow
12 Prepress
14 Press
25 Postpress
27 Saphira Consumables
28 Systemservice
31 Factors for Calculating Savings
32 Heidelberger Druckmaschinen AG
3

Environmental Management
Conserving resources, minimizing emissions,
and reducing waste
4

Environmental goals –akey strategy. Heidelberg®
takes an integrated approach to the environment. The
company has long been committed toconserving re­
sources and minimizing emissions and waste in manu­
facturing processes. Environmental protection has
been an integral part ofthe company’s philosophy for
more than 30 years. In 2006, the Management Board
Member for Engineering and Manufacturing presented
the company’s first balanced scorecard for the en­
vironment, which sets out measures for Heidelberger
Druckmaschinen AG and documents environmental
targets up to 2010. The largest plant in Wiesloch­
Walldorf and the sites in Amstetten, Brandenburg, Kiel,
Leipzig and Ludwigsburg all comply with the guide­
lines of the international ISO 14001:2004 standard.
When it comes to offering comprehensive solutions
for eco­friendly printing, Heidelberg leads the way in
the industry. Our activities focus on three areas:
1. Reducing and avoiding CO 2
•Reducing paper waste
Paper has the largest environmental impact in the
printing process, accounting for upto90percent
of aprint job’s CO 2footprint. Therefore, reducing
paper waste doesn’t just cut unnecessary paper
costs, but also significantly improves the environ­
mental impact. The following Heidelberg products
play akey role in cutting waste:
­ Integration of the entire production process
with Prinect®, the print shop workflow
­ Prinect spectrophotometric systems for fast
and precise color measurement and control,
inline sheet inspection systems for quality
control during the print process
­ The Anicolor® inking unit
­ The CutStar® short­grain sheeter for producing
sheets in the required format
•Reducing energy consumption
Energy consumption during production has the
second highest impact on CO 2 emissions after
paper. Weare constantly working to cut the
energy consumption of our products. This can
be seen, for example, in products such as the
Suprasetter® A52/A75 and Star peripheral systems
such as the AirStar® air supply cabinet and
DryStar® dryer.
•Carbon-neutral presses
Heidelberg isthe only printing press manufacturer
to offer carbon­neutral presses.
2. Reducing and avoiding emissions
Reducing or, better still, avoiding emissions makes
akey contribution to environmental protection and
protects the health of employees at the workplace.
This is achieved by:
•Saving on washing agents and powder with
products like our blanket washup devices or the
PowderStar® AP 500 powdering system
•Saving on dampening solution with the FilterStar®
and FilterStar compact
•Reducing VOCs with Heidelberg solutions for
IPA­reduced and IPA­free printing
•Reducing noise through sound-absorbing dampers
and noise protection for all relevant machine parts
3. Reducing and avoiding waste
As well as reducing paper waste, itisalso impor­
tant to cut or avoid other forms of waste as much
as possible in all areas ofthe production process.
Examples include:
•Saphira® Chemfree plates for the Suprasetter
•Less residual ink by using the InkStar®
ink supply system
•Reduced wastewater by using the two-stage filtra­
tion systems FilterStar and FilterStar Compact
5

Aperfect CO 2 balance through financing climate
protection projects
Offsetting CO 2 emissions through
project financing
How to make your sheetfed offset press carbon­
neutral. The processes involved in the production,
transportation, and installation of sheetfed offset
presses produce acertain volume of CO 2.Materials
usually account for between 70 and 80 percent of
the CO 2 produced, while energy and logistics account
for the remaining 20–30 percent. Heidelberg offers
you the opportunity tooffset these emissions by co­
financing aclimate protection project. Customers
can participate inaproject by purchasing emissions
certificates, which are accredited by recognized
environmental protection organizations. Environmen­
tal impact assessment experts ensure that financial
resources are invested effectively in the project. All
sheetfed offset presses from Heidelberg can be
purchased with aclimate certificate.
6
Energy consumption determines
carbon dioxide emissions.
Saving energy pays dividends –for you and the
environment. Each kilowatt­hour of energy generated
releases aparticular quantity ofcarbon dioxide (CO 2).
Greenhouse gases play amajor role in global warming
as it is produced whenever energy sources containing
carbon (coal, oil, gas) are burned, for example:
•1liter of heating oil equates to 2.6 kgofCO 2
•1liter of gasoline equates to 2.4 kgofCO 2
•1liter of diesel equates to 2.6 kgofCO 2
Therefore, measures such as heat recovery at the
press and savings in energy consumption don’t just
reduce energy costs significantly, but also result in
quantifiable CO 2 savings.
If 300 tons of paper are saved each year by system­
atically automating the printing process, this equates
to the CO 2 absorption capacity ofathree­hectare
wood over ten years*. To take aconcrete example:
If you lower CO 2 emissions by 20 tons in one year
with the Speedmaster® SM 52­4 Anicolor, this equates
to the CO 2 absorption capacity of2,000 m² of forest
over 10 years.
*0.1 hectares of forest have aCO 2absorption
capacity of1ton/year.

The environmental impact of running
asheetfed press
During their lifetime, all printing presses consume
energy and paper and produce wastewater and emis­
sions. The chart below evaluates various production­
related factors onaSpeedmaster XL105­6+L that
outputs 36 million sheets ayear, with an average run
length of 8,000 sheets per job and 18 jobs per day.
Producing up to 4,830 tons of CO 2,paper is the biggest
Environmental impact of inputs on the printing process
Input
Proportion of waste after processing
Paper
4,059 t/a
CO 2:4830 t/a
Waste paper 283 t/a
CO 2:340 t/a
Energy
560,000 kWh/a
CO 2:320 t/a
Ink
54 t/a
Ink residues
2t/a
Alcohol
7,200 l/a
VOC 6,500 l/a
contributor to the CO 2 footprint, with about 5–10
percent of this amount being classified as waste.
Energy is the second biggest contributor, producing
340 tons of CO 2.
Cleaning agent
2,400 l/a
VOC 1,200 l/a
True to scale: Paper
accounts for byfar the
largest share.
Water
35,000 l/a
Wastewater
3,200 l/a
Powder
900 kg/a
Powder emissions
60 kg/a
7

Paper
Reducing paper waste isthe no. 1priority.
Reducing paper waste plays akey role in environmental
protection.
In the print process, paper alone accounts for be­
tween 60 and 90 percent of total CO 2 emissions.
Approximately 1,190 kgofCO 2is released during the
production of 1,000 kg of paper made of virgin fiber.
No matter whether you are aiming specifically to re­
duce CO 2emissions or are more interested insaving
money, reducing paper waste should be your no. 1
priority.
Heidelberg offers awide range ofproduct solutions
designed to significantly reduce paper waste. CutStar,
for example, cuts sheets from areel and allows you
to adjust the sheet size tothe actual length required.
By saving just 1millimeter on each printed sheet, you
could reduce annual paper waste by up to 4tons,
thus cutting CO 2 emissions by 4.75 tons. Savings are
even greater ifthe paper format differs significantly
from standard formats. If you opt to complement your
press with CutStar, you will, ofcourse, also benefit
from the actual material cost savings offered by using
reels instead ofsheetfed stocks. Standardizing the
8
entire printing environment is one of the key factors
in reducing makeready waste. This process includes
achieving stable temperatures and humidity levels
in both the paper store and printing area to eliminate
most ofthe negative influences acting on the paper.
In other words, standardizing the press and its produc­
tion parameters, using standardized consumables,
and printing “by number” significantly cuts the number
of waste sheets produced.
Potential savings
Annual savings by reducing the format
by just 1millimeter:
Paper Energy CO 2
4t – 4.75 t

Did you know that paper fibers can be recycled up to six times?
Selecting the right paper cuts
CO 2 emissions.
Look for quality labels and recycled fibers. Choosing
the right paper can lead tosignificant reductions in
CO 2 emissions.
Remember to buy paper made of raw materials
obtained from sustainable forests and look for the FSC
(Forest Stewardship Council) or PEFC (Program for
the Endorsement of Forest Certification Schemes) qual­
ity labels. FSC certification entitles your print shop
to use the official FSC label.
Recycled fibers have similar properties to non-
recycled paper. Therefore, it makes sense to use paper
with ahigh proportion of recycled materials. The
European paper recycling ratio is currently 62 percent,
which equates to around 50 million tons of recycled
stocks every year. Asevery ton of recycled paper pro­
duces around 8–9 percent less CO 2than virgin stocks,
it reduces CO 2 emissions in Europe alone by up to 4.5
million tons.
9

Paper savings per makeready process
Workflow
Process control with Prinect, the print shop
workflow, results in major paper savings.
Less waste, greater environmental protection. Using
certain Prinect production workflow modules cuts
paper waste considerably, achieving savings of up to
200 tons ayear onaSpeedmaster XL105. This is
equivalent to cutting CO 2 emissions by 238 tons.
•
•
•
10
Basis:
500 sheets
Prinect Pressroom Manager® –for transferring CIP3
data from prepress for greater accuracy in presetting
the ink zone profile
Prinect Color Assistant® –learning preset charac­
teristic curves to ensure acontinuous improvement
in ink fountain preset values
Prinect
Pressroom
Manager:
­50 sheets
Prinect production workflow throughout the makeready process
can achieve savings of several hundred tons of paper ayear.
Prinect Image Control®/Prinect® Axis Control® –
spectrophotometric color control of the entire image
(Prinect Image Control) or the color bar (Prinect
Axis Control) to achieve and maintain target values
Prinect
Color
Assistant:
­50 sheets
•
Prinect Inpress Control® –spectrophotometric
inline measurement system for maximum produc­
tivity. It measures and controls color and register
on the fly and at any speed in the color bars.
By saving just 100 sheets in every makeready pro­
cess, you will reduce the overall paper waste of aB1
press by34.5 tons, which is equivalent to 41 tons of
CO 2 every year.
Prinect
Image
Control/
Prinect
Axis Control:
­100 sheets
Potential savings
Annual savings by reducing makeready waste
by 100 sheets:
Prinect
Inpress
Control:
­100 to
­150 sheets
Paper Energy CO 2
34.5 t – 41 t

Quality innext tonotime. Prinect Inpress Control
adjusts color and register inline immediately, resulting
in minimum paper consumption. The target values
are reached quickly and the press can often gostraight
into good sheet production. As shown on the previous
page, values drawn from actual practice reveal aver­
age savings of between 100 and 150 sheets per make­
ready process. Aswell as reducing startup waste, this
system also cuts production times and lowers energy
consumption.
Prinect Inpress Control is also an effective instrument
for quality assurance. Continuous inline measurements
and closed loop corrections ensure stable color set­
tings throughout the production run.
The perfect harmony and interaction of Heidelberg
Prinect components –including presetting of the ink
zones, presetting of control systems and Prinect
Inpress Control –can easily lead to savings of between
300 and 350 sheets per makeready process and take
8to12minutes off the entire makeready time.
Prinect Inpress Control is available for the
following Heidelberg sheetfed offset presses:
•
•
•
•
•
•
•
Speedmaster XL75
Speedmaster SM102
Speedmaster CD102
Speedmaster CX102
Speedmaster XL105
Speedmaster XL145
Speedmaster XL162
Prinect Inpress Control –the spectrophotometric inline measuring
system for maximum productivity
Potential savings
Annual savings thanks tointegration with
Prinect and Prinect Inpress Control:
Time Paper Energy CO 2
666.6 h 103 t – 122 t
11

Energy consumption
Prepress
Suprasetter –state-of-the-art CtP systems
maximize energy efficiency
Computer­to­plate conserves resources. When invest­
ing in aCtP system, you should not limit your purchas­
ing criteria to quality and cost alone. Choosing the
correct solution also helps protect the environment.
CtP systems consume most electrical energy in the
platesetting and development stages. They also emit
waste heat. Heidelberg has set itself the task of maxi­
mizing productivity and minimizing these emissions.
The latest generation of highly efficient laser diode
systems, integrated automation modules, state­of­the­
art low­current components and modern cooling
systems combine to ensure that the Suprasetter A
series offers the lowest power consumption and heat
emission ratings on the market. The recorder itself
consumes only 0.7 kilowatt­hours. These savings can
be increased further still in combination with the
more efficient wash/gum unit aligned with the Saphira
Chemfree plate. The combined consumption amounts
to just 2.6 kilowatt­hours. When comparing the
12
Previous generation
4­up CtP systems
Platesetters inthe Suprasetter range are some of the most
economical CtP systems on the market.
Suprasetter A
­80%
Suprasetter Amachine outputting Saphira Chemfree
plates with older devices energy consumption is cut by
up to 80 percent .
Potential savings
Savings over conventional platesetters
per 1,000 hours ofoperation:
Water Energy CO 2
– 3,800 kWh 2.17 t

Prepress
Saphira Chemfree plates –reduce environmental
pollution and avoid high disposal costs.
The Saphira Chemfree plate offers environmentally friendly plate
production without the use of developers and replenishers.
Greater environmental protection, lower costs.
The chemical development of printing plates presents
anumber of challenges for print shops. Stable pro­
cesses and strict quality control are needed for consist­
ent plate output, which in turn reduces waste and
cuts makeready times on presses. This is one of the
key benefits of the Saphira Chemfree plate over
thermal process­based alternatives.
On presses, Saphira Chemfree plates behave in ex­
actly the same way asconventional plates. They can
be used with standard inks and dampening solution
additives and there isnoneed to adjust the dosage.
Unlike aconventional plate processor, the ‘wash/
gum’ unit for Saphira Chemfree plates does not use a
continuous water supply, and therefore saves 12 liters
of water perplate, equating to 350,000 litersevery year.
Savings can also be made in terms of the chemical
waste produced. Compared to atraditional thermal
plate, waste is reduced by afifth toanannual figure
of just 300 liters.
Another notable difference isinterms of the energy
consumption. The Chemfree solution has an energy
overhead of just 1.9 kilowatt­hours, which is less
than half the energy required to drive the equivalent
processing equipment, when specified at 5kilowatt­
hours.
Potential savings
Chemfree plate savings per 1,000 hours
of operation:
Water Energy CO 2
350,000 l 3,100 kWh 1.77 t
13

Press
Research &development with the environment
in mind
Using alternative energies can reduce CO 2 emissions to zero.
Each kilowatt­hour of power saved reduces CO 2 emis­
sions. It is with this maxim in mind that Heidelberg
designs and uses energy­efficient components, prod­
ucts, and peripherals. For example, the main drive and
vast majority ofauxiliary motors are all brushless
synchronous sinusoidal motors. These very compact
motors not only offer amuch longer service life and
wear­free operation but are also much quieter and
output less electromagnetic interference. As aresult,
they improve overall energy efficiency by up to 30
percent compared to other popular motors. Reactive
power (power that generally becomes waste heat)
is minimized.
14
Heidelberg isthe only printing press manufacturer
to employ these sinusoidal synchronous main drive
motors. Using this technology generates savings of
up to 10,000 kilowatt­hours or5.72 tons of CO 2 per
annum for aSpeedmaster XL105­10­P that is
operated 24/7.
Potential savings
Annual savings by choosing more efficient
main drive motors:
Paper Energy CO 2
– 10,000 kWh 5.72 t

Paper savings per setup operation
Press
Environmental effect of Anicolor short-inking
unit technology.
Speedmaster SM52with
conventional inking unit
Comparing conventional offset printing and printing with Anicolor
Up to 90 percent less paper waste. When it comes to
cutting paper consumption, the Anicolor short­inking
unit from Heidelberg has the biggest impact. Anicolor
inking technology achieves the required color values
after only 40 startup sheets, resulting in an 80 percent
saving compared to the 200 startup sheets required by
atraditional offset press with conventional inking unit.
Combined with Print Color Management PCM (a
system­wide calibration of all print­related processes
developed by Heidelberg specialists), makeready
waste can becut by as much as 90 percent on the
Speedmaster SM52Anicolor. Based on 4,500 jobs
per year and an average paper weight of 100 gsm,
this cuts CO 2 emissions by 15.7 tons ayear.
Speedmaster
SM 52 Anicolor
­80%
Potential savings
Annual savings with Anicolor
technology:
Speedmaster SM52
Anicolor with Print Color
Management
­90%
Paper Energy CO 2
13.2 t – 15.7 t
15

Press
The AirStar system halves power consumption.
Double efficiency. Heidelberg ispursuing acompletely
new approach to the air supply. Todate, the AirStar air
supply cabinet is the only system that uses ahighly
efficient, fast­running turbo radial blower.
The AirStar system has been developed in­house by
Heidelberg and, with an efficiency rating of 70 percent,
achieves aperformance level more than double that
of conventional side channel blowers (30 percent). On
long presses in particular, the energy consumed in
producing the same volume of air can becut by at
least half.
Afrequency converter also ensures that only
the volume of air actually required is generated. On
aSpeedmaster XL105­10­P, this delivers annual
savings of up to 40,000 kilowatt­hours, which is
equivalent to 23 tons of CO 2.
16
Turbo radial blowers are more than twice as efficient
as side channel blowers.
Potential savings
AirStar boosts efficiency –more air for
less CO 2:
Paper Energy CO 2
– 40,000 kWh 23 t

Press
Star system –innovative filter system supports
alcohol-free printing.
Significantly less wastewater. Minimized alcohol
(3 percent) and, increasingly, alcohol­free printing is
becoming more important in optimizing environmen­
tal protection and maximizing cost savings. For every
percentage drop inalcohol, annual alcohol consump­
tion can bereduced by up to 1,200 liters.
Heidelberg supports these efforts with fine filtration
using an innovative two­stage filter system.
The filtration system, integrated into the CombiStar®
Pro, stabilizes the printing process and extends the
replacement intervals for dampening solution by a
factor of between three and six. It also extends the
service life ofthe dampening solution from 2–4 weeks
to 4–12 months.
On the Speedmaster XL105­10­P, this equates to a
reduction in wastewater of at least 2,000 liters ayear.
FilterStar extends the replacement intervals for the dampening
solution by afactor of between three and six.
Potential savings
Dampening solution filtration saves
water and time:
Time Water CO 2
10 h 2,000 l –
17

Press
Alcohol-free printing with CombiStar Pro.
CombiStar Pro isahigh-end unit for very demanding applications.
Alcohol­minimized and alcohol­free printing. The use
of alcohol in dampening solutions is ahotly discussed
topic. Alcohol supports the printing process byre­
ducing the surface tension of the dampening solution,
moistening the plate more efficiently, cooling as are­
sult of its continuous evaporation, and preventing the
growth of bacteria and algae. However, alcohol evapo­
rates completely, thereby resulting in the formation of
ground­level ozone –orsummer smog.
18
Heidelberg offers solutions that allow you to switch
to alcohol­free and alcohol­minimized printing while
maintaining optimum print quality. This is made
possible by:
•Equipping the dampening system with water
pan and dampening form rollers that are more
hydrophilic
•The right Saphira dampening solution additive
•Precise adjustment of the dampening system
•Filtration of the dampening solution
•Integrated inking unit temperature control of the
CombiStar Pro for integrated dampening solution
preparation and inking unit temperature control
CombiStar Pro also ensures the inking unit is pre­
heated when the press starts up and cooled during
the production run. Startup and production run waste
are cut thanks tothe constant temperatures of the
printing plate, ink, and blanket.
The benefits are considerable –minimizing or dis­
pensing with alcohol in the printing process, saving
money, protecting the environment, and –not least –
safeguarding employees’ health. For amedium-sized
business with several presses, this can easily result
in five­figure cost savings year­on­year.

External
temperature
18°C
Press
‘Free-cooling’ device ensures the CombiStar
Pro operates largely autonomously.
Free cooling in the CombiStar Pro saves energy thanks
to intelligent control technology.
Inking unit cooling without arefrigeration unit.
The CombiStar combines inking unit temperature con­
trol and cooling plus dampening solution treatment
in one system. The ‘free­cooling’ concept integrated
into the latest CombiStar Pro model uses the same
cooling water that circulates in water­cooled peripher­
als to maintain the temperature ofthe inking unit.
The refrigerating unit is activated –automatically –
only when external temperatures exceed 18°C.
Certain climatic conditions, such as those in the UK,
for example, make itpossible to operate the CombiStar
Pro without using the refrigeration unit for 60–70 per­
cent of the time. This control technology reduces ener­
gy costs by several thousand Euro per year.
Activation of refrigerating unit at external temperatures
>18°C
70% free cooling
Cooling of the inking unit during seven out
of ten production hours using cooling water
circulation for the peripheral systems
19

Press
Environmentally friendly and cost-effective
InkStar system
The InkStar cartridge system ensures economical and environmentally
friendly use of valuable ink.
20
All the benefits of automatic ink feed. Ink waste
represents the third largest environmental factor in
offset printing. InkStar, the environmentally friendly
automatic ink supply system, cuts ink residue waste
and reduces the disposal frequency for empty metal
ink containers. Nearly all the ink is removed from the
ink cartridge, leaving just about 0.5 percent as waste,
which is ten times less than the 4percent of waste
generated by regular ink containers.
Quality benefits –the fill level in the ink fountains
remains the same thanks toultrasonic metering, ensur­
ing that the printing conditions remain constant.
The 2kgcartridges are easy tochange and store,
which makes InkStar an efficient and clean system
that is easy to handle.
InkStar covers almost the entire range ofoffset inks,
including process, PMS, and even metal pigmented or
UV inks (in special light-protected cartridges). They
also benefit from air­sealed ink containers that enable
unfinished cartridges to be stored for many months.
Potential savings
Annual savings for every ton
of used ink:
Ink Energy CO 2
35 kg – –

Press
InkStar Direct –central ink supply via
distribution network
Central ink supply with InkStar Direct
User­friendly, clean ink logistics. InkStar Direct
facilitates the central supply of ink to presses via
adistribution network.
The InkStar cartridge can easily be replaced by a
valve insert. Large, cost­effective, and refillable ink
containers with acapacity ofbetween 25 and 1,000
kilograms are usually used. And, if aspot color is need­
ed in aprinting unit at some point, the valve can
be replaced by the required ink cartridge injust afew
seconds.
The system is aclean solution that allows almost
all the ink to be used up, thus cutting disposal costs
considerably and consuming far less washup solution.
InkStar Direct is available for Speedmaster presses
with four or more inking units, including Speedmaster
XL 105, SM102, CD102, CX102, XL75, and SM 74.
21

Press
DryStar –maximized energy efficiency with
in-house dryer concept
Integrated DryStar concept offers highest efficiency.
Distance from the dryer to the substrate. By properly
integrating dryers into the delivery of apress with a
coating unit, you can cut energy costs significantly.
Heidelberg isthe only press manufacturer to offer a
dryer concept developed in­house. The distance be­
tween the dryer modules and the printed sheet is a
key factor in maximizing dryer efficiency. With each
centimeter that this distance isreduced, the efficiency
of an IR dryer increases by 5percent.
When coated jobs account for 60percent of press out­
put, DryStar dryers (using 20 percent less energy than
competitors) generate savings of between 40,000
and 60,000 kilowatt­hours. This cuts CO 2 emissions
by around 29 tons every year.
22
Alternatively, the press can run 20–30 percent
faster while consuming the same amount of energy.
Ultimately, this results in lower CO 2 emissions per
1,000 sheets.
Potential savings
DryStar IR reduces energy costs and
the CO 2 footprint:
Paper Energy CO 2
– 50,000 kWh 28.6 t

Press
DryStar UV –perfect integration in the
press design
Innovative reflector coating boosts efficiency.
The increase in efficiency achieved by minimizing
the distance between the dryer module and sheet of
paper also applies to UV dryers.
Efficiency is increased by as much as 10 percent
for every centimeter this distance isreduced. The
UV lamps in the DryStar UV are 20millimeters
(0.79 inches) closer to the substrate than any other
system on the market. The use of innovative di­
chromatic reflector surfaces raises the energy effi­
ciency level from astandard 91percent to 99.5
percent.
Each UV lamp releases acertain amount of un-
wanted long-wave IR band energy. Heidelberg solves
this problem with awater­cooled housing that ab­
sorbs 90 percent of the long­wave rays and associated
heat. Other systems are much less efficient at re­
moving waste heat. The innovative Heidelberg design
helps cut energy consumption by between 10 and
15 percent, thereby saving up to 70,000 kilowatt­hours
or 40 tons of CO 2 each year.
DryStar UV is 20 percent more efficient than other dryers.
Potential savings
DryStar UV reduces energy costs and
the CO 2 footprint:
Paper Energy CO 2
– 70,000 kWh 40 t
23

Press
Water cooling is cost-effective and good
for the environment.
Water cooling delivers major energy savings
on Heidelberg presses.
The thermal capacity ofwater is around four times
higher than that of air. Water cooling is available on
larger presses as an option for cooling peripheral
devices. The facts speak for themselves:
•
•
•
•
•
24
The thermal capacity ofwater is around four times
greater than that of air.
Far less energy is required to transport coolants
than is needed for air cooling.
The cooling water circulates in aclosed cycle;
impurities are all but eliminated.
When using air cooling, the air discharged outside
needs to be replaced by fresh air, which requires
air conditioning.
The climate inthe pressroom can beimproved and
standardized considerably.
Equipping aSpeedmaster XL105­10­P with water
cooling technology produces savings of up to 10,000
kilowatt­hours ayear, equivalent to areduction of
5.7 tons of CO 2.
Potential savings
Water­cooled peripherals standardize the
printing environment and save energy:
Paper Energy CO 2
– 10,000 kWh 5.7 t

Postpress
Automation reduces energy consumption
and paper waste.
Stahlfolder KH 82 combination folder reduces setup time from
45 minutes to less than 10 minutes.
Potential of automation. Automatic presetting options
on postpress machines from Heidelberg speed up the
makeready process and cut paper waste considerably.
Enhancements in postpress automation, for exam­
ple, help you cut setup waste further still for the
Stahlfolder® KH 82 compared to the Stahlfolder KH 78.
The annual reduction in paper waste pays dividends
for the environment –and your wallet.
The Stitchmaster® ST 450 saddlestitcher also mini­
mizes waste and saves resources. Each feeder is driven
by its own servomotor, thus assuring perfect quality –
even if the machine stops –without any unnecessary
paper waste. This results in savings of several tons
of paper each year and optimizes both your workflow
and costs.
Automation devices for cutting energy con­
sumption, makeready times, and materials are
available for:
•Stahlfolder folding machines
•Stitchmaster saddlestitchers
•Eurobind® adhesive binders
•Polar Mohr cutters
•Varimatrix® and Dymatrix® die cutters
•Diana® folder gluers
Potential savings
Stitchmaster ST450 saves time, cuts energy
costs and improves the CO 2 footprint:
Time Paper Energy CO 2
833 h – 14,000 kWh 8t
25

Postpress
Perfect binding saves energy.
The energy­saving functions of the Eurobind Pro
are anexample of the measures taken by Heidelberg
in the postpress stage. For instance, the intelligent
machine control system switches unneeded compo­
nents to standby, deactivates certain spine prepa­
ration modules depending on the type of binding re­
quired, and reduces production to crawl speed if a
defined waiting time is exceeded. The system returns
to full production speed within ashort time when
needed.
The optional strip milling cutter, which enables paper
strips to be recycled, also brings economic and environ­
mental benefits. Milling dust nolonger needs to be
disposed of as special waste at considerable expense.
26
Cost-effective and eco-friendly operation: the Eurobind Pro

Saphira Consumables
The right decision –environmental awareness,
print quality, and high press output
Saphira iskind on the environment –and your budget.
Ecology and economy gohand in hand. Ecological
printing is not incompatible with quality and machine
performance. The quality ofthe consumables plays a
major role in this respect. This is why Saphira con­
sumables are carefully selected based on their print­
ing characteristics and environmental criteria, and
tested for compatibility.
Our policy is based on three key pillars:
•
•
•
Substitution: Wherever possible, our Saphira
consumables replace mineral and synthetic compo­
nents with renewable raw materials (for example,
vegetable oil replaces mineral oil in inks).
Reduction: Where materials used in consumables
cannot yet be substituted, we have significantly
reduced any harmful environmental impact they
might have. This has more than just environmental
benefits –using highly pigmented inks, for example,
cuts ink consumption by up to 15 percent.
Offsetting: It is not possible to entirely eliminate
consumables from the carbon footprint generated
by aprint product. Nonetheless, ink accounts for
less than 2to3percent. The carbon footprint can
be offset by purchasing emission credits.
Ecological. More and more Saphira products now
have “Eco” as part oftheir designation. Saphira Eco
products significantly reduce the burden on the envi­
ronment and meet or even surpass all statutory re­
quirements and industrial safety and performance
standards. They are based on renewable raw materi­
als and, for the most part, are recyclable. They also
contain no substances of very high concern (SVHC)
and comply with all the requirements of the REACH
directive.
27

Systemservice
Proactive maintenance –akey practice
for the protection of the environment
Systematic maintenance maximizes service life and has apositive
impact on the environment.
Regular maintenance leads to less waste and
lower energy consumption. Machines and systems
from Heidelberg offer high levels of reliability and a
long service life. Therefore, you won’t be surprised to
hear that we keep unplanned service call­outs and
replacement to aminimum.
However, production technology needs regular
and systematic care and maintenance toensure it
continues to operate smoothly in the long term.
Heidelberg therefore places the proactive maintenance
of machines and systems at the heart ofits technical
services offering.
Our preventive maintenance programs include
thorough check­ups, fine­tuning, and replacement of
wearing parts at individually defined intervals. We
have special checklists for all Heidelberg products and
presses, which can beused to check quickly and
precisely what needs to be done. We also offer main­
tenance training that will teach your team how to
28
maintain your equipment’s performance over time.
By minimizing equipment failure and enabling the
early detection of potential problems, our preventive
maintenance programs reduce waste, energy consump­
tion and the use of consumables. Thanks tomore
reliable and efficient production, service call­outs and
the associated travel can bekept to aminimum.
For the benefit of the environment and your peace
of mind, we recommend at least one maintenance visit
per year for all Heidelberg equipment.

Systemservice
Fewer engineer call-outs thanks to Remote
Services
Remote Service and eCall –systematic and proactive support
via the Internet
Remote Services reduce costs and lower CO 2
emissions. Thanks toour Remote Services technology,
you can grant Heidelberg service engineers direct
access toyour equipment over the Internet. This en-
ables us to perform abroad range ofservices online
that are traditionally provided on-site. These include
preventive inspections, troubleshooting, diagnosis,
application support, and even user training.
The latest addition to our portfolio is the emergency
support service eCall®. In the event of amalfunction,
your equipment automatically generates an eCall,
which is sent simultaneously to you and to your
Heidelberg service organization. With asimple click,
you can immediately send arequest for remote
support. AHeidelberg expert then analyzes your data
and calls you back within the shortest possible time.
In up to 70 percent of cases –such as setting,
application, or process errors –the problem can be
identified and resolved the very first time the service
expert and press operator speak onthe phone.
Our Remote Services reduce downtime, the need for
call-outs, and associated costs. Replacement of parts
can bescheduled for atime that is most convenient
for you. Fewer miles reduces logistical CO 2 emissions.

Systemservice
Print Color Management –delivering
system-wide sustainability
Stable, standardized processes are essential for cost-effective
and economical production.
Print Color Management puts you in full control.
Quality iskey if you want to be in complete control of
your production processes. Our Print Color Manage-
ment service supports you in system-wide calibration
with proof, plate making, and offset printing.
With practical training on equipment and presses,
your staff are equipped with the tools they need to
design workflows quickly and efficiently –from data
input to the finished print product.
The system enhances production conditions while
also minimizing the risk of error. This results in smooth
workflows, savings in energy and materials, and
much greater added value.
Print Color Management makes adirect contribution
toward conserving the full range ofresources.
30

Factors for Calculating Savings
The following factors apply for the calculation
examples in this guide:
Printing plate production
•
•
36,000 plates per year
(50 percent ea. 4/4 resp. 5/5)
Plate format 81.1 ×105.5 cm (31.93 ×41.54 in)
Print process format 75 ×105 cm (29.53 ×41.34 in)
•
•
•
•
Speedmaster XL105-10-P
30 million sheets per year
(format 900 ×640 ×0.115 mm)
4,200 makeready processes per year
7,500 sheets per job
Print process format 37 ×52cm(14.57 ×20.47 in)
•Speedmaster SM52-4-H
•Speedmaster SM52-4-H Anicolor
•4,500 makeready processes per year
•2,000 sheets per job
•Speedmaster SM52-8-P
•Speedmaster SM52-8-P Anicolor
•3,600 makeready processes per year
•2,000 sheets per job
31

Heidelberger Druckmaschinen AG
Heidelberg, atradition-based yet technology-focused pioneer, issynonymous with innovative,
top-class products and services. Each solution is developed with one goal in mind –toboost the
success ofyour business. Heidelberg solutions cover the entire process and value-added chain
of sheetfed offset printing, from management and prepress topress and postpress. We ensure
that you can improve your production processes, making them better, faster, more cost-effective,
and more environmentally friendly. Our portfolio is designed to increase your productivity, flexibility,
and quality –all crucial factors when it comes to satisfying your customers.
32

Products from Heidelberg promise
peak performance inprint quality,
speed, and reliability inthe format
classes 35×50to121×162 cm.
The Prinect printshop workflow
integrates and optimizes all working
processes in printshops, thus boost-
ing the efficiency of production
workflows, ensuring greater process
transparency, and accelerating the
entire job flow.
Heidelberg Systemservice offers you the widest range ofservices
for your company –from technical service with state-of-the-art remote
diagnosis and original service parts, to optimization of print results
and process consulting. With Saphira consumables from Heidelberg,
you can besure that you are using process materials designed
to perfectly match the requirements of your Heidelberg equipment.
Heidelberg Financial Services provides you with the advice and
support required to meet your financing needs. In addition, Heidelberg
Business Consulting offers business management advice.
The Print Media Academy in Germany isthe center of aworldwide
network –currently covering 18 sites –and offers acomprehensive training
program tailored specifically to the requirements of the industry. Intensive
training courses have been designed to provide participants with in-depth
information on Heidelberg products, technological innovations, and
successful management.
We’d love to hear from you. If you would like more information on
Heidelberg solutions to suit your needs, please don’t hesitate tocontact us.
33

Heidelberger Druckmaschinen AG
Kurfuersten-Anlage 52–60
69115 Heidelberg
Germany
Phone +49 6221 92-00
Fax +49 6221 92-6999
www.heidelberg.com
Publishing Information
Printed in: 09/10
Photographs: Heidelberger Druckmaschinen AG
Platemaking: Suprasetter
Printing: Speedmaster
Finishing: Stahlfolder, Stitchmaster
Consumables: Saphira
Fonts: HeidelbergGothicMl
Printed in Germany
The mark
of responsible
forestry
GFA-COC-001569
Trademarks
Heidelberg, the Heidelberg logotype, AirStar, Anicolor, Axis Control,
CombiStar, CutStar, DryStar, Diana, Dymatrix, eCall, Eurobind,
FilterStar, the HEI logotype, InkStar, PowderStar, Prinect, Prinect
Color Assistant, Prinect Image Control, Prinect Inpress Control,
Prinect Pressroom Manager, Saphira, Speedmaster, Stahlfolder,
Stitchmaster, Suprasetter, Systemservice and Varimatrix are
either registered trademarks ortrademarks ofHeidelberger
Druckmaschinen AG in the U.S. and other countries. All other
trademarks are the property of their respective owners.
Subject to technical modifications and other changes.
For details on the emissions of our products please visit us at
www.heidelberg.com/emissiondetails
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